Transfer Case Assembly

Reassembly Steps
! 1. Transfer case
! 2. Counter gear
! 3. Sub gear
4. Bellville spring
5. Spacer
6. Ball bearing
! 7. Snap ring
8. Ball bearing
9. Snap ring
10. Counter gear assembly
11. Bearing snap ring
12. Front Output shaft
13. Ball bearing
14. Clutch hub and sleeve
15. Needle bearing
! 16. Front output gear
! 17. Sub gear
! 18. Belleville spring
! 19. Spacer
! 20. Sub gear snap ring
! 21. Bearing collar
22. Ball bearing
! 23. Snap ring
24. Front Output gear assembly
25. Bearing snap ring
26. Plate
27. Ball
28. Bearing collar
29. Needle bearing
30. Transfer input gear
31. High-low block ring
! 32. High-low synchronizer assembly
! 33. Mainshaft end lock nut
! 34. Ball bearing
35. Snap ring

Important Operations !

NOTE: Details of the service procedure are provided for "Important Operations" only, marked with "!" above. Pay close attention to these steps.





1. Transfer Case
1) Cover the shaft spline with adhesive tape [1]. This will prevent damage to the oil seal lip [2].





2) Apply recommend liquid gasket or its equivalent to the transfer case fitting surfaces.
3) Tighten the transfer case bolts to the specified torque a little at a time.

Transfer Case Bolt Torque: kg-m(lb-ft/N-m)
3.8 ± 0.8 (27.5 ± 5.8/39.24 ± 7.84)





2. Counter Gear
3. Sub Gear
Apply chassis grease to the sub-gear and the counter gear thrust surfaces.













7. Snap Ring
1) Select a snap ring that will allow the minimum axial play.
2) Use a pair of snap ring pliers to install the snap ring to the counter gear.
Bearing and Snap Ring Clearance: mm(in)
Standard: 0 - 0.1(0 - 0.0039)





16. Front Output Gear
17. Sub Gear
18. Belleville Spring
19. Spacer
Apply engine oil to the thrust surfaces of the sub-gear, the belleville spring, and the spacer.





20. Sub Gear Snap Ring
21. Bearing Collar
Use a bench press to install the needle bearing and collar together with the front output gear.













23. Snap Ring
1) Select a snap ring that will allow the minimum axial play.
2) Use a pair of snap ring pliers to install the snap ring to the Output shaft.

Bearing and Snap Ring Clearance: mm(in)
Standard: 0-0.1(0-0.0039)





32. High-Low Synchronizer Assembly
Turn the shallow clutch hub face [1] toward the side of the sleeve with small groove [2] on the outer circumference.





NOTE: The clutch hub groove [A] must be aligned with the key groove of sleeve.





Sub Gear Preload
1) Hook a length of piano wire over one of the sub-gear teeth.
2) Attach the other end of the piano wire to a spring balancer.
3) Measure the sub-gear preload.

Sub-Gear Preload: kg(lb/N)
Standard: 5 - 12 (11.0 - 26.5/49.0 - 117.6)





33. Mainshaft End Lock Nut
1) Use the lock nut wrench to tighten the mainshaft end lock nut to the specified torque.
Lock Nut Wrench : J-37219

Mainshaft End Lock Nut Torque: kg-m(lb-ft/N-m)
13 ± 1 (94.0 ± 7.2/129.4 ± 9.8)

2) Stake the lock nut.





34. Ball Bearing
Use the ball bearing installer to install the ball bearing.
Installer: J-37223